Electrical housing with non-integral cable outlet port member

ABSTRACT

A housing for electrical devices such as connectors, circuit breakers, and fuse panels. A cable outlet port member is separate from the housing to provide unidirectional resistance to movement of a cable relative to the housing. The non-integral relationship permits the members to be replaced in the event of damage. A busbar formed by a stamping and bending operation is also disclosed for use in combination with conventional circuit breakers.

FIELD OF THE INVENTION

This invention relates to housings for electrical devices such asconnectors, fuses, and circuit breakers and, more particularly, to animproved housing having a non-integral cable de-tensioning member whichis removably attached to the housing for simple economical replacementin the event of breakage. This invention also relates to an improvedbusbar for attachment to circuit breakers and to a method of making sucha busbar.

BACKGROUND OF THE INVENTION

Housings for electrical devices, such as connectors, circuit breakers,and fuse panels, are used in many applications, including recreationalvehicles such as motor homes and boats. In a typical application, thehousing receives multiple cables for connection to devices within thehousing and to carry electrical power to a number of devices outside ofthe housing. It is good practice to use de-tensioning devices within thehousing to insure that electrical connections between the cables and thedevices within the housing are not strained or stressed if tension isapplied to the cable at some point outside the housing, an event whichcommonly occurs during installation and/or service.

One way to provide a de-tensioning structure is to mold a port into apanel of the housing having opposing resilient fingers defining a narrowslit-like aperture which unidirectionally resists passage of anelectrical cable through the aperture. In short, the fingers permit theinsertion of the cable into the housing but resist any movement in theopposite direction such as may occur if the cable were tugged or pulledat some point outside of the housing.

The problem with this approach is that the opposed fingers which make upthe anti-tensioning device are frequently broken off duringinstallation. Under these circumstances, good practice requiresdiscarding and replacing the entire housing. Where the housing iscomplex, such a practice is costly and time consuming.

SUMMARY OF THE INVENTION

A first aspect of this invention is the creation and provision of animproved housing for electrical devices having a non-integral; i.e.,separately formed electrical cable outlet port member which provides thedesired de-tensioning characteristic but which, because it is formedseparately from the housing, can be economically and quickly replaced ifbroken during the installation or servicing procedures.

The non-integral outlet port member and its association with the housingcan take any of several shapes and configurations, two of which aredisclosed in detail in this document. In one form, an essentiallyrectangular member is screwed or snapped to a rear panel of the housing.In another form, the member is configured so as to slide into an openingin a side panel of the housing and be retained by a separate cover.

Another aspect of the invention is the provision of an inexpensive,easily formed busbar for mounting within an electrical device housing toreceive a plurality of conventional circuit breakers and make electricalconnections therewith. The improved busbar can be manufactured bycreating an inexpensive stamping and thereafter bending portions of thestamping to produce the plurality of spaced, parallel stabs. In theconfiguration disclosed herein, the spacing between the stabs isindependent of the height of the stabs.

Other objects, advantages and applications of the present invention willbecome apparent to those skilled in the art when the followingdescription of the best mode contemplated for practicing the inventionis read in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The description herein makes reference to the accompanying drawingswherein like reference numerals refer to like parts throughout theseveral views, and wherein:

FIG. 1 is an exploded perspective view of an electrical distributionhousing embodying one form of the inventive; cable outlet port memberand the inventive busbar,

FIG. 2 is a plan view of the outlet port member in the combination ofFIG. 1;

FIG. 3 is a sectional view along section line 3—3 of the device of FIG.2;

FIG. 4 is an exploded perspective view of the second embodiment of thecable outlet port invention.

FIG. 5 is a sectional view of the device of FIG. 4;

FIG. 6 is an exploded, detailed view of the device of FIG. 5 showing themanner in which it is removably attached to the housing;

FIG. 7 is a detail of the busbar in the device of FIG. 1;

FIG. 8 is an exploded perspective detail of the busbar from the deviceof FIG. 1; and

FIG. 9 is a plan view of the busbar of FIGS. 7 and 8 at an intermediatestage in the manufacturing process.

DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS OF THE INVENTIONS

While the invention has been described in connection with what ispresently considered to be the most practical and preferred embodiment,it is to be understood that the invention is not to be limited to thedisclosed embodiments but, on the contrary, is intended to cover variousmodifications and equivalent arrangements included within the spirit andscope of the appended claims, which scope is to be accorded the broadestinterpretation so as to encompass all such modifications and equivalentstructures as is permitted under the law.

Referring now to FIGS. 1 through 3, a molded plastic housing 10 of thesize, weight, and configuration suitable for use as an electricaldistribution center in recreational vehicles is shown. The housing 10 isinjection molded from a suitable phenolic resin to exhibit a decorativeand functional front peripheral flange 12, a separate snap-in cover 14having edge tabs 13 and an access patch 16 having edge tabs 17 whichcooperates with the removable cover 14.

The housing is further provided with an integral, rigid, rear panel 18having formed therein an essentially rectangular opening having aperipheral edge 20 adapted to removably receive, a molded plastic outletport member 22 having electrical cable ports 23 defined by opposedresilient plastic fingers 24 which are designed to unidirectionallyresist passage of an electrical cable 43 there through and to omitpermit passage of the cable in the opposite direction. Holes 26 areprovided in the member 22 to receive screws 27 which enter into bosses28 formed in the panel 18 so that the port member 22 may be removablyattached to the housing 10. As shown in FIGS. 2 and 3 device may also beremovably connected to peripheral edge 20 by edge tabs 44 which snapinto corresponding slots 45 together with lip 47 being received intorecess 48. However, the non-integral relationship also permits themember 22 to be removed from the housing 10 and replaced if one or moreof the fingers 24 is broken during installation and/or servicing. It isunderstood that a wide variety of attachments mechanisms are availableto removably attach member 22 to housing 10.

Housing 10 further comprises an interior panel 30 which essentiallydivides the interior of the housing into AC and DC sections, the ACsection being the larger section on the left, as shown in FIG. 1. On theDC side, a fuse panel 32, receiving a plurality of standardautomotive-type fuses 34, is provided. On the AC side, the panel 30 isconfigured to receive an aluminum busbar 36 hereinafter described indetail. Conventional circuit breakers 38 are mounted on the stabs of thebusbar 36 in a spaced, parallel stack as shown in FIG. 1. Obviously,other configurations and/or interior arrangements may be provided.

Additional electrical connective devices such as the junction blockshown at 40 may be provided on the interior of the housing 10. Inaddition, the rear panel 18 is provided with knockouts 42 for cablerouting purposes.

Because of the non-integral nature of the member 22 with the housing 10,a number of members 22 may be taken to the job site and readilysubstituted into the place of the original member should one or more ofthe fingers 24 be broken off during the installation or servicingprocedure. When this occurs during servicing, the non-integral nature ofthe member 22 allows it to be removed and replaced without loss of thede-tensioning feature which good electrical service and installationpractice requires.

Referring now to FIGS. 4-6, a second embodiment of the invention as itpertains to the non-integral outlet port member and its configurationwill be described. In these figures, a molded plastic housing 30 isprovided with such size and configuration as to be suitable for use as atransfer box in recreational vehicles and other applications. Thehousing 50 comprises a number of panels forming a box-like structure;one of these panels is a side panel 52 having a rectangular openingformed therein. The opening 54 receives a cable outlet port member 56having a rectangular strip-like configuration and fingers 74 and 76which permit the member to slide into and out of the opening 54 as shownin more detail in FIG. 6.

The housing 50 receives any of a number of different types of electricaldevices, in this case, a snap-in bracket 58 carrying connectors 60. Atop panel 62 of the housing 50 is provided with knock-outs 64 for cablerouting purposes. A cover 66 of injection molded plastic construction isprovided with edge loops 68 operating with tabs 70 on the housing 50 toprovide a snap-on relationship.

As shown in FIG. 5, the member 56 is provided with opposed resilientplastic fingers 71 which define a plurality of spaced parallel ports tounidirectionally permit passage of cables 72 but to resist withdrawal ofthe cables from the housing. As described above, fingers 74 and 76 areformed on the opposite edges of the member 56 to straddle the peripheraledge 34 of the opening in the housing 50 so that the member 56 can beeasily positioned in or removed by a simple sliding action whicheliminates the necessity of screws or other separate fasteners. A detail78 is molded integrally with the housing panel to stabilize the centerof the member 56 in the installed condition.

Referring now to FIGS. 7, 8, and 9, an improved busbar 36 suitable foruse in the device of FIG. 1 is shown. The busbar comprises the stamped,aluminum plate 80 having a plurality of regularly spaced parallel stabs82 projecting from one lateral edge thereof and defined in part byL-shaped slots for apertures 84 in the plate 80. The apertures 84 opento the edge of the plate from which the stabs 82 project.

The configuration of the busbar 36; i.e., flat and planar, is shown inFIG. 9 as formed by a simple stamping operation. Thereafter, the stabs82 are bent or folded out of the plane of the plate 80 along fold lines86 to provide the configuration shown in FIG. 8. It will be noted thatin this configuration the height of the stabs 82 is independent of thelateral spacing between them. Therefore, tall stabs 82 suitable for usewith conventional and contemporary circuit breakers may be providedwithout requiring additional space in between the stabs which increasespacing would, in turn, increase the overall size of the housing 10. Asshown in FIG. 8, the busbar 36 fits onto and into the panel 30 by meansof a number of strategically shaped flanges 88 forming spaced pockets90. The busbar 36 may be used in any application where a plurality ofcircuit breakers are disclosed in stacked; i.e., spaced parallelrelationship within a housing.

1. For use in combination with an electrical system housing of the typehaving one or more rigid panels and an opening defined by at least oneof said panels comprising: an electrical cable outlet port member havinga first end and a second end, said member being separate from butremovably attachable to said housing in substantial registry with saidopening; said member comprising a plurality of cable outlet ports, eachdefined by integrally molded opposed plastic fingers forunidirectionally resisting passage of an electrical cable there through,said member includes at least one tab on said first end for engaging atleast one mating slot in said housing and said member housing having atleast one notch for providing a snap fit connection between said housingand said second end of said member.
 2. The apparatus as defined in claim1 wherein said panel defines a flange and a seat surrounding saidopening, said member in the installed position resting on said seatwithin said flange.
 3. The apparatus as defined in claim 1 furthercomprising screws for removably attaching the outlet port member to thehousing.
 4. The apparatus as defined in claim 1 wherein said membercomprises fingers to receive and straddle the peripheral edges of saidopening so that the member may slide into and out of said opening. 5.The apparatus as defined in claim 4 further comprising a coverattachable to said housing for retaining said member within saidopening.
 6. In combination comprising: a housing for electrical devicesincluding at least one panel having an opening formed therein; and anelectrical cable output port member having a first end and a second endadapted to be removably secured to said panel in substantial registrywith said opening; said outlet port member comprising the a plurality ofcable outlet ports each defined by integrally molded opposed plasticfingers for unidirectionally resisting passage of an electrical cablethere through, said member includes at least one tab on said first endfor engaging at least one mating slot in said housing and said memberhousing having at least one notch for providing a snap fit connectionbetween said housing and said second end of said member.
 7. Theapparatus as defined in claim 6 wherein said panel further comprises aperipheral flange and a seat around said opening, said member in theinstalled position resting within said opening and on said seat, saidcombination further comprising means for securing said member withinsaid opening.
 8. The apparatus as defined in claim 7 wherein said meanscomprises screws.
 9. The apparatus as defined in claim 6 wherein saidmember is formed with peripheral fingers which straddle the peripheraledge of said opening in the installed position whereby said member mayslide into and out of said opening.
 10. The apparatus as defined inclaim 9 further comprising a cover which is removably securable to saidhousing for retaining said member in the installed position.
 11. Theapparatus as defined in claim 10 wherein said cover is plastic.
 12. Theapparatus as defined in claim 11 wherein said housing has a peripheralmounting flange.
 13. The apparatus as defined in claim 6 furthercomprising a conductive metallic busbar mounted to said housing andhaving a plurality of regularly spaced, parallel stabs projecting intothe carrier of said housing to receive circuit breakers in operableassociation therewith.
 14. The apparatus as defined in claim 13 whereinsaid stabs are flat planar elements disclosed in parallel spacedrelationship with one another and integral with a base plate.
 15. Theapparatus as defined in claim 1 wherein said panel further comprises aperipheral flange and a seat around said opening, said member in theinstalled position resting within said opening and on said seat, saidcombination further comprising means for securing said member withinsaid opening.
 16. The apparatus as defined in claim 15 wherein saidmeans comprises screws.